Influence of Selective Laser Melting Process Parameters on Microstructure and Properties of a Typical Ni-Based Superalloy

doi:10.1007/s40195-022-01401-x

Abstract

Abstract:

The influence of selective laser melting (SLM) process parameters on the microstructure and mechanical properties of a typical Ni-based superalloy was researched. The optimum parameters of P = 170 W, V = 0.8 m/s were determined, under which the SLMed samples exhibited both the largest relative density of 99.57% and the best mechanical properties, including the microhardness (329.3 ± 3.8 HV), yield strength (726 ± 8.1 MPa), ultimate tensile strength (900 ± 5.9 MPa) and elongation ((31.9 ± 0.24)%). The average grain size ranges of SLMed samples are from 15.2 to 17.4 μm, with a typical mixed grain structure. Owing to the high cooling rate and remelting during SLM process, a large number of low-angle grain boundaries (LAGBs), dislocations and sub-grains were formed, and the fraction of LAGBs reached above 65%. At the same time, the content of low-Σ coincidence site lattice (CSL) boundaries was mostly less than 1%, while there was almost no γ′ phase precipitated in the matrix. The texture of SLMed samples was weak, and there was no obvious preferred growth direction. Combining with the microstructure characterization, both grain refinement strengthening and dislocation strengthening were considered as the main strengthening mechanisms. Moreover, the fracture mechanism of the optimum sample belonged to ductile fracture.

Key words: Selective laser melting, Ni-based superalloy, Relative density, Microstructure, Mechanical property

Zhen Lu, Chengcai Zhang, Nana Deng, Haiping Zhou, Ruirui Fang, Kuidong Gao, Yukuo Su, Hongbin Zhang. Influence of Selective Laser Melting Process Parameters on Microstructure and Properties of a Typical Ni-Based Superalloy[J]. Acta Metallurgica Sinica (English Letters), 2022, 35(10): 1673-1687.

Figures/Tables 15

Table 1 Element composition of the GH99 alloy powders (mass%)

Ni	Cr	W	Co	Mo	Al	Ti	Fe	C
Bal	18.51	6.05	6.11	4.25	2.3	1.41	0.104	0.0078

Fig. 1a SEM micrograph of the GH99 powders, b distribution of particle size

Fig. 2 Schematic diagram of SLM process

Table 2 Experiment design of SLM processes

Samples	Laser power, P (W)	Scanning speed, V (m/s)
1	150	0.8
2	150	1.0
3	150	1.2
4	170	0.8
5	170	1.0
6	170	1.2
7	190	0.8
8	190	1.0
9	190	1.2

Fig. 3 Dimensions of square and tensile samples

Fig. 4 OM images of SLMed GH99 samples with different SLM parameters

Fig. 5 a Relative density distribution under different SLM parameters, b curve of relative density versus volume energy density

Fig. 6 Microstructures of sample 4: a OM image and b SEM image

Fig. 7 IPF maps and grain size distribution of SLMed GH99 samples: a Sample 1, c Sample 4, e Sample 5, g Sample 6, i Sample 7; PF maps of SLMed GH99 samples: b Sample 1, d Sample 4, f Sample 5, h Sample 6, j Sample 7

Fig. 8 OIM maps and misorientation angle distribution of SLMed GH99 samples: a Sample 1, b Sample 4, c Sample 5, d Sample 6, e Sample 7; f the fraction of HAGBs, LAGBs, and ΣCSL in these samples

Fig. 9 KAM maps of SLMed GH99 samples: a Sample 1, b Sample 4, c Sample 5, d Sample 6, e Sample 7

Fig. 10 TEM images of SLMed samples: a-c dislocation tangles of samples 6, 7 and 4, respectively; d SAD pattern of matrix of sample 4; e sub-grains boundaries of sample 4; f sub-grains of sample 4

Table 3 Mechanical properties of SLMed GH99 samples

Samples	Microhardness (HV)	YS (MPa)	UTS (MPa)	EL (%)
1	307.5 ± 3.1	713 ± 7.9	887 ± 5.7	28.9 ± 0.16
2	285.7 ± 3.0	618 ± 6.9	798 ± 5.3	25.8 ± 0.19
3	258.6 ± 3.3	574 ± 6.8	697 ± 4.6	14.9 ± 0.17
4	329.3 ± 3.8	726 ± 8.1	900 ± 5.9	31.9 ± 0.24
5	296.1 ± 3.6	659 ± 6.9	858 ± 5.3	30.8 ± 0.20
6	283.7 ± 3.2	572 ± 6.9	774 ± 5.1	25.1 ± 0.17
7	299.7 ± 3.5	654 ± 7.2	842 ± 5.8	29.3 ± 0.19
8	312.1 ± 3.2	719 ± 6.9	889 ± 4.2	29.8 ± 0.20
9	291.2 ± 2.9	632 ± 6.9	804 ± 5.0	27.3 ± 0.18

Fig. 11 Mechanical properties of SLMed samples: a microhardness and b stress-strain curves

Fig. 12 Fracture microstructures of samples 3, 4 and 7: a-c sample 3, d-f sample 4, g-i sample 7

References 45

[1]	A. Deshpande, S.D. Nath, S. Atre, K. Hsu,Metals 10, 629 (2020)
[2]	S. Ma, X. Lv, J. Zhang, Y. Zhang, P. Li, H. Jin, W. Zhang, X. Li, S. Mao, J. Alloys Compd. 743, 372 (2018)
[3]	I. Galilea, B. Ruttert, J. He, T. Hammerschmidt, R. Drautz, B. Gault, W. Theisen, Addit. Manuf. 30, 100874 (2019)
[4]	Y.L. Kuo, T. Nagahari, K. Kakehi,Materials 11, 996 (2018)
[5]	W. Wei, J. Xiao, C. Wang, Q. Cheng, F. Guo, Q. He, M. Wang, S. Jiang, C. Huang, Mater. Sci. Eng. A 831, 142276 (2022)
[6]	O. Sanchez-Mata, X. Wang, J.A. Muiz-Lerma, S.E. Atabay, M. Brochu, J. Alloys. Compd. 865, 158868 (2021)
[7]	D. Alexey, P. Anna, M. Igor, B. Philippe, P. Nathalie, D. Benjamin, S. Sebastien, D. Christophe, Addit. Manuf. 15, 66 (2017)
[8]	K. Osakada, M. Shiomi, Int. J. Mach. Tool Manuf. 46, 1178 (2006)
[9]	Y. Guo, Z. Gong, C. Li, B. Gao, P. Li, X. Wang, B. Zhang, X. Li, Chem. Eng. J. 392, 123682 (2020)
[10]	H. Attar, M. Calin, L.C. Zhang, S. Scudino, J. Eckert, Mater. Sci. Eng. A 593, 170 (2014)
[11]	S. Sun, Q. Teng, Y. Xie, T. Liu, R. Ma, J. Bai, C. Chao, Q. Wei, Addit. Manuf. 46, 102168 (2021)
[12]	V.S. Sufiiarov, E.V. Borisov, I.A. Polozov, Appl. Mech. Mater. 698, 333 (2015)
[13]	M. Benoit, M. Mazur, M. Easton, M. Brandh, Int. J. Adv. Manuf. Technol. 114, 915 (2021)
[14]	X. Huang, H. Chen, B. Liu, R. Mohammadzadeh, J. Li, Q. Fang,Optik 243, 167456 (2021)
[15]	Y. Zhao, Z. Ma, L. Yu, J. Dong, Y. Liu, J. Mater. Sci. Technol. 68, 184 (2021)
[16]	C. Zhen, S. Chen, Z. Wei, L. Zhang, B. Lu, S. Zhang, Y. Xiang, Prog. Nat. Sci. 28, 496 (2018)
[17]	B. Cheng, J. Gu, M. Song, Mater. Sci. Eng. A 790, 139704 (2020)
[18]	H. Zhang, K. Zhang, Z. Lu, C. Zhao, X. Yang, Mater. Sci. Eng. A 604, 1 (2014)
[19]	H. Li, H. Wei, H. Peng, T. Lin, J. Feng, Y. Huang,Intermetallics 34, 69 (2013)
[20]	Y. Hu, X. Lin, Y. Li, J. Wang, W. Huang, J. Alloys Compd. 800, 163 (2019)
[21]	Y. Bai, Y. Yang, D. Wang, M. Zhang, Mater. Sci. Eng. A 703, 116 (2017)
[22]	Z. Chen, Z. Wei, P. Wei, S. Chen, B. Lu, J. Du, J. Li, S. Zhang, J. Mater. Eng. Perform. 26, 5897 (2017)
[23]	X. Zhao, Q.S. Wei, N. Gao, E.L. Zheng, Y.S. Shi, S.F. Yang, J. Mater. Process. Technol. 270, 8 (2019)
[24]	A. Luca, C. Kenel, S. Griffiths, S. Joglekar, D. Dunand, Mater. Des. 201, 109531 (2021)
[25]	J. Han, J. Yang, H. Yu, J. Yin, M. Gao, Z. Wang, X. Zeng, Rapid Prototyp. J.23, 217 (2017)
[26]	Y. Bai, Z. Shi, J. Yan, H. Wang, J. Mater. Process. Technol. 280, 116597 (2020)
[27]	T. Voisin, J. Forien, A. Perron, S. Aubry, N. Bertin, A. Samanta, A. Baker, Y. Wang, Acta Mater. 203, 116476 (2021)
[28]	Y. Zhao, Q. Guo, Z. Du, S. Chen, J. Tan, Z. Yang, Z. Ma, Mater. Sci. Eng. A 832, 142505 (2022)
[29]	K. Small, Z. Clayburn, R. DeMott, S. Primig, D. Fullwood, M. Taheri, Mater. Sci. Eng. A 785, 139380 (2022)
[30]	D. Ahmadkhaniha, H. Mller, C. Zanella, J. Mater. Eng. Perform. 30, 6588 (2021)
[31]	G. Casalino, S. Campanelli, N. Contuzzi, A. Ludovico, Opt. Laser Technol. 65, 151 (2015)
[32]	S. Li, Q. Wei, Y. Shi, Z. Zhu, D. Zhang, J. Mater. Sci. Technol. 31, 946 (2015)
[33]	S. Qin, H. Zhang, J. Liu, W. Zheng, J. Mater. Res. 31, 1348 (2016)
[34]	O. Gokcekaya, N. Hayashi, T. Ishimoto, K. Ueda, T. Narushima, T. Nakano, Addit. Manuf. 36, 101624 (2020)
[35]	H. Zhang, S. Qin, H. Li, J. Liu, Y. Lv, Y. Wang, P. Zhang, H. Zhou, T. Wu, J. Mater. Res. 34, 321 (2018)
[36]	S. Shakerin, A. Hadadzadeh, B. Amirkhiz, S. Shamsdini, M. Mohammadi, Addit. Manuf. 29, 100797 (2019)
[37]	K. Han, S. Qin, H. Li, J. Liu, H. Zhou, Mater. Charact. 158, 109936 (2019)
[38]	B. Almangour, J. Yang, Mater. Des. 110, 914 (2016)
[39]	C. Kmbab, B. Gmdba, B. Bka, B. Djta, Acta Mater. 199, 19 (2020)
[40]	D. Tomus, Y. Tian, P. Rometsch, M. Heilmaier, X. Wu, Mater. Sci. Eng. A 667, 42 (2016)
[41]	T. Vilaro, C. Colin, J. Bartout, L. Naze, M. Sennour, Mater. Sci. Eng. A 534, 446 (2012)
[42]	K. Kunze, T. Etter, J. Grsslin, V. Shklover, Mater. Sci. Eng. A 620, 213 (2014)
[43]	C. Man, C. Dong, T. Liu, D. Kong, D. Wang, X. Li, Appl. Surf. Sci. 467-468, 193 (2019)
[44]	N. Hansen, Scr. Mater. 51, 801 (2004)
[45]	F. Greulich, L. Murr, Mater. Sci. Eng. 39, 81 (1979)